Power distribution unit with contactors with integrated pre-charge circuit

Abstract

A power distribution unit (100) includes a housing (106), a main contactor (102) in a main cavity (110) of the housing, and a pre-charge assembly (104) in a secondary cavity (112) of the housing. The main contactor includes first and second stationary contacts (120), and a movable contact (122) configured to electrically connect the first and second stationary contacts in a mated position. The main contactor includes a coil assembly (140) energized to move the movable contact. The pre-charge assembly includes a pre-charge resistor (202) and a pre-charge switch (204) coupled to the pre-charge resistor. The power distribution unit includes a controller (240) received in the housing. The controller includes a main contactor driver (242) to power the main contactor and a pre-charge driver to power the pre-charge switch.

Description

Technical Field

[0001] The main topic of this article is power distribution units. Background Technology

[0002] In certain electrical applications, such as HVAC, power supply, locomotives, elevator control, motor control, aerospace applications, electric vehicles, hybrid electric vehicles, fuel cell vehicles, and charging systems, electrical contactors are used to control the power distribution of devices. For example, vehicles using high-voltage battery packs typically include a main contactor to switch battery power to power electronic components. There are usually some capacitors associated with the power electronic circuitry. When the main contactor is closed, such capacitors can generate large inrush currents. These large inrush currents can create arcing across the contacts, damaging or reducing their lifespan and generating sparks. To eliminate large inrush currents and protect the main contactor, a pre-charging circuit is typically used in conjunction with the main contactor.

[0003] A typical pre-charge circuit includes a pre-charge contactor connected in series with a pre-charge resistor. During vehicle power-up, the pre-charge contactor closes, and current flows through the pre-charge contactor and the pre-charge resistor. When the required voltage is reached, the main contactor can be opened, and the pre-charge contactor can be closed. In a conventional power distribution unit, the various components are grouped together and electrically connected using wires and busbars. For example, the individual components are mounted to a common frame, such as using fasteners. Wiring connects the components, for example, using terminals, contactors, or connectors between the components. Assembling a power distribution unit is very time-consuming, requiring individual mechanical and electrical connections for each component. Furthermore, the large number of components occupies a significant amount of space within the vehicle.

[0004] The problem to be solved is to provide a power distribution unit that can be assembled in a cost-effective and reliable manner. Summary of the Invention

[0005] The aforementioned problem is addressed by a power distribution unit comprising a housing having walls defining a main cavity and a secondary cavity. The power distribution unit includes a main contactor received in the main cavity of the housing. The main contactor includes first and second fixed contacts, and a movable contact movable between a mating position and an unmatting position. The movable contact engages the first and second fixed contacts to electrically connect them in the mating position. The movable contact is separated from the first and second fixed contacts in the unmatting position. The main contactor includes a coil assembly energized to move the movable contact between the unmatting and mating positions. The power distribution unit includes a pre-charge assembly received in the secondary cavity of the housing. The pre-charge assembly includes a pre-charge resistor and a pre-charge switch coupled to the pre-charge resistor. The power distribution unit includes a controller received in the housing. The controller includes a main contactor driver for powering the main contactor. The controller also includes a pre-charge driver for powering the pre-charge switch. Attached Figure Description

[0006] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0007] Figure 1 This is a schematic diagram of a vehicle having a mating unit according to an exemplary embodiment.

[0008] Figure 2 This is a diagram of the power distribution unit of a vehicle battery system according to an exemplary embodiment.

[0009] Figure 3 This is an exploded view of a power distribution unit according to an exemplary embodiment.

[0010] Figure 4 This is a perspective view of a power distribution unit according to an exemplary embodiment. Detailed Implementation

[0011] Figure 1 This is a schematic diagram of a vehicle having a power distribution unit 100 according to an exemplary embodiment. The vehicle 10 may be an electric vehicle. In various other embodiments, the vehicle 10 may be a hybrid electric vehicle, for example, including an engine (not shown). The vehicle 10 includes one or more electric motors 12 for driving the wheels 14 of the vehicle 10. An inverter 16 is provided to control the power supply to the electric motors 12.

[0012] Vehicle 10 includes a vehicle battery system 18 for providing power to vehicle 10, such as an electric motor 12 or other vehicle systems or components. A power distribution unit 100 is part of the vehicle battery system 18. The vehicle battery system 18 includes a battery pack 20, such as a high-voltage battery pack 20 for powering the electric motor 12. The battery pack 20 provides a high-voltage DC output. The battery pack 20 is electrically connected to the power distribution unit 100. The power distribution unit 100 is also electrically connected to the electric motor 12. In addition to providing energy to the electric motor 12, the battery pack 20 can provide energy to other vehicle electrical systems, such as heaters, compressors, low-voltage DC components, etc. The vehicle battery system 18 may include other system components, such as DC-DC converters. The electric motor 12 can operate as a generator to charge the battery pack 20, providing fuel economy advantages and reducing pollutant emissions.

[0013] A power distribution unit 100 is disposed between the battery pack 20 and the inverter 16. The power distribution unit 100 controls the power supply between the battery pack 20 and the inverter 16. The power distribution unit 100 includes a main contactor 102 and a pre-charge assembly 104 integrated with the main contactor 102. The main contactor 102 is an electrical switch or relay that safely connects and disconnects one or more circuits to protect the flow of power through the system. The pre-charge assembly is used to pre-charge the capacitors of the vehicle battery system 18 and includes an electrical switch or relay and a resistor for safely pre-charging the capacitors. The power distribution unit 100 can be used in various other applications besides vehicles, such as HVAC, power supply, locomotives, elevator control, motor control, aerospace applications, electric vehicles, hybrid electric vehicles, fuel cell vehicles, charging systems, etc.

[0014] In an exemplary embodiment, vehicle 10 includes a vehicle controller 40 electrically connected to the cooperating unit 100. The vehicle controller 40 sends a trigger signal to the power distribution unit 100 to operate the power distribution unit 100. The power distribution unit 100 controls the power supply to the inverter 16. For example, the power distribution unit 100 includes a driver for turning switches on and off to provide power to the inverter 16. The driver operates based on the trigger signal from the vehicle controller 40. In an exemplary embodiment, multiple switches are operated based on a single trigger signal sent from the vehicle controller 40 to the power distribution unit 100. The trigger signal may be based on a request for battery power, such as turning a key or pressing a start button on vehicle 10, plugging in a charger (e.g., a mobile phone charger), operating other vehicle systems (e.g., the heating / cooling system of vehicle 10), or other requests for vehicle power.

[0015] Figure 2This is a diagram of the power distribution unit 100 of the vehicle battery system 18. The power distribution unit 100 is electrically connected between the battery pack 20 and a load 30, such as the inverter 16 of the electric motor 12. The vehicle battery system 18 includes a positive circuit 32 and a negative circuit 34. The positive circuit 32 is connected to the positive battery terminal 22 of the battery pack 20. The negative circuit 34 is connected to the negative battery terminal 24 of the battery pack 20. The main contactor 102 and the pre-charge assembly 104 of the power distribution unit 100 are electrically connected to the positive circuit 32. The negative contactor 36 is connected to the negative circuit 34. A capacitor 38 is connected between the positive circuit 32 and the negative circuit 34.

[0016] In an exemplary embodiment, the main contactor 102 may be in the open position by default, disconnecting the battery pack 20 from the load 30. In the open position, the battery pack 20 does not supply power to the load 30. A signal or request to close the main contactor 102 may be issued by the vehicle controller 40, for example, in response to an ignition request from a driver or other events, such as connecting a charger or connecting the battery pack 20 to other devices whenever needed. The power distribution unit 100 includes a controller 240 for controlling the power supply through the power distribution unit 100. The controller 240 includes a main contactor driver 242 for controlling the opening and closing of the main contactor 102. The controller 240 includes a precharge driver 244 for controlling the opening and closing of the precharge assembly 104. Communication of the opening and closing signals may be via a discrete signal connector or a serial communication bus between the vehicle controller 40 and the controller 240 of the power distribution unit 100. The precharge assembly 104 is used to charge the capacitor 38 before closing the main contactor 102. The pre-charge component 104 is activated before the main contactor 102 to charge the capacitor 38 before the main contactor 102 is activated. For example, the controller activates the pre-charge driver 244 before activating the main contactor driver 242, for example, at a predetermined time (e.g., approximately 100 ms) before activating the main contactor driver 242. When the main contactor 102 is turned on, the pre-charge component 104 minimizes the inrush current through the main contactor 102 by minimizing the voltage difference. The pre-charge component reduces or eliminates the problem of closing the main contactor 102 due to large inrush currents. For example, the pre-charge component 104 can reduce arcing across the main contactor 102 during switching. The current flowing through the pre-charge component 104 can be limited to a value significantly less than the rated current of the load being pre-charged. For example, the current can be limited to a value of 5 amps or less, while the rated load current can be hundreds of amps. Limiting the current affects the rate of voltage increase of the load 30. The time required for the capacitor 38 to charge can be set to a predetermined amount of time, such as approximately 100 ms. In an exemplary embodiment, controller 240 controls the pre-charge sequence and transfers control responsibility from vehicle controller 40. Transferring responsibility from vehicle controller 40 reduces the overhead of the vehicle's main electronic control unit. Controller 240 controls the sequence of closing the pre-charge switch to allow capacitor 38 to charge. Controller 240 monitors capacitor charging to control the opening of the pre-charge switch and the closing of the main contactor 102. Controller 240 may use a control algorithm to determine when the capacitor has sufficient charge (e.g., based on timing or current sensing). When capacitor 38 has sufficient charge, controller 240 energizes the main contactor 102 and closes the pre-charge switch. Controller 240 protects the main contactor 102 from damage.

[0017] The pre-charge assembly 104 is positioned parallel to the main contactor 102. One side of the pre-charge assembly 104 is electrically connected to the battery pack 20. The other side of the pre-charge assembly 104 is electrically connected to the capacitor 38 and the load 30. A controller 240 of the pre-charge assembly 104 controls the operation of the pre-charge assembly 104, for example, by providing a control signal to activate the pre-charge assembly 104 and to activate the main contactor 102 after the capacitor 38 has been charged. The control signal may be a signal that controls a switching device (e.g., the gate drive of a MOSFET). The control signal may be a voltage or current applied to the switching device. The control signal may be a voltage or current applied to the coil assembly.

[0018] Figure 3 This is an exploded view of a power distribution unit 100 according to an exemplary embodiment. The power distribution unit 100 includes a housing 106 that holds a main contactor 102, a pre-charging assembly 104, and a controller 240. The housing 106 includes walls 108 forming a main cavity 110 and a secondary cavity 112. The main cavity 110 holds the main contactor 102, and the secondary cavity 112 holds the pre-charging assembly 104. Both the main cavity 110 and the secondary cavity 112 are integrated within a common housing 106. The housing 106 is a one-piece housing having walls 108 forming the main cavity 100 and walls 108 forming the secondary cavity 112, co-molded as a single, monolithic structure. In the illustrated embodiment, the main cavity 110 has a circular cross-section, and the secondary cavity has a rectangular cross-section; however, in alternative embodiments, the cavities may have other shapes.

[0019] In an exemplary embodiment, one of the walls 108 of the housing 106 is a partition wall 114 located between the main cavity 110 and the secondary cavity 112. The partition wall 114 defines a portion of the main cavity 110 and a portion of the secondary cavity 112. A first side of the partition wall 114 faces the main cavity 110 and a second side of the partition wall 114 faces the secondary cavity 112. The housing 106 includes a mounting flange 116, for example at the bottom, configured for mounting within the vehicle 10.

[0020] The housing 106 includes a cover 118 for closing the main cavity 110 and a cover 119 for covering the secondary cavity 112. Optionally, the cover 118 and / or the cover 119 may be sealed to the wall 108 of the housing 106.

[0021] The power distribution unit 100 includes a fixed contact 120 received in a main cavity 110 and a movable contact 122 movable within the main cavity 110 between a mating position and an unmatting position. The movable contact 122 engages the fixed contact 120 to electrically connect the fixed contact 120 in the mating position. The fixed contact 120 is fixed to a housing 106. For example, the fixed contact 120 may be coupled to a contact holder 124 received in the main cavity 110. The contact holder 124 includes an opening 126 for receiving the fixed contact 120. The contact holder 124 defines a housing 128. The fixed contact 120 extends into the housing 128. The movable contact 122 is received in the housing 128 and configured to engage the fixed contact 120 when the main contactor 102 is operated.

[0022] Each fixed contact 120 includes a terminating end 130 and a mating end 132. The terminating end 130 is configured to terminate to another component, such as an electrical wire or busbar, such as an incoming busbar or an outgoing busbar. In an exemplary embodiment, the terminating end 130 is exposed externally to the distribution unit 100 for termination to other components. The terminating end 130 may be threaded to receive a nut. In the illustrated embodiment, the terminating end 130 extends through and over the cover 118. The terminating end 132 is located within the main cavity 110 to mate with a movable contact 122, for example, when the distribution unit 100 is energized. In the illustrated embodiment, the mating end 132 is substantially flat to engage the movable contact 122. However, in alternative embodiments, the mating end 132 may have other shapes, such as a circular shape, to form a mating protrusion at the mating end 132 for engaging with the movable contact 122.

[0023] The power distribution unit 100 includes a coil assembly 140 in the main cavity 110, operable to move a movable contact 122 between an unengaged position and an engaged position. The coil assembly 140 includes a winding or coil 142 wound around a core 144 to form an electromagnet. The coil assembly 140 includes a plunger 146 coupled to the core 144. The movable contact 122 is coupled to the plunger 146 and is movable with the plunger 146 during operation of the coil assembly 140. The coil assembly 140 includes a spring 148 for returning the movable contact 122 to the disengaged position when the coil assembly 140 is de-energized. In an exemplary embodiment, the coil assembly 140 includes an outer core 150 configured to be received in the main cavity 110. The coil 142 is configured to be received in the outer core 150.

[0024] In an exemplary embodiment, the power distribution unit 100 includes an arc suppressor 152 for suppressing electric arcs in the circuit. The arc suppressor 152 is located in a cavity 110 of the housing 106. Optionally, the arc suppressor 152 may be located in a contact holder 124, for example, in or near a housing 128. In an exemplary embodiment, the arc suppressor 152 includes a magnet that forms a magnetic field in the housing 128 to suppress arcs formed between the movable contact 122 and the fixed contact 120. In an exemplary embodiment, the contact holder 124 may be sealed and filled with an inert gas for arc suppression.

[0025] Housing 106 holds components of power distribution unit 100. Housing 106 includes a first end 160 and a second end 162 opposite to the first end 160. The first end 160 may be the top of housing 106, and the second end 162 may be the bottom of housing 106. Housing 106 includes a first side 164 and a second side 166 opposite to the first side 164. A main cavity 110 is disposed on the first side 164. A secondary cavity 112 is disposed on the second side 166. In the illustrated embodiment, the main cavity 110 is open at the first end 160. The main cavity 110 receives the main contactor 102 through the open first end 160. A cover 118 is coupled to housing 106 at the first end 160 to close the main cavity 110. In the illustrated embodiment, the secondary cavity 112 is open on the second side 166. The secondary cavity 112 receives the pre-charge assembly 104 through the open second side 166. In an exemplary embodiment, the secondary cavity 112 holds controller 240. Cover 119 is attached to housing 106 on the second side 166 to enclose and retain pre-charge assembly 104 in secondary cavity 112. Pre-charge assembly 104 and main contactor 102 are housed in the same housing 106. Controller 240 and main contactor 102 are also housed in the same housing 106. Power distribution unit 100 does not require a second housing for pre-charge assembly 104 or controller 240, thus reducing the number of parts and assembly time.

[0026] The cover 118 is configured to be coupled to the housing 106 at a first end 160. The cover 118 includes an opening 170 for receiving a retaining contact 120. The opening 170 aligns with the opening 126. The cover 118 is shaped to fit within the housing 106, for example, within the main cavity 110. The cover 118 is made of a dielectric material, such as a plastic material. In an exemplary embodiment, the cover 118 includes an isolator 172 having an isolation wall 174 configured to electrically isolate the termination end 130 of the retaining contact 122. The isolator 172 is made of a dielectric material, such as a plastic material.

[0027] In an exemplary embodiment, housing 106 includes a contact passage 180 between a main cavity 110 and a secondary cavity 112. In the illustrated embodiment, the contact passage 180 is located within a partition wall 114. The contact passage 180 allows the contact to pass between the main cavity 110 and the secondary cavity 112.

[0028] The precharge assembly 104 is received in the secondary cavity 112. The precharge assembly 104 includes a control circuit board 200, one or more precharge resistors 202 coupled to the control circuit board 200, and a precharge switch 204 coupled to the control circuit board 200. The control circuit board 200 forms part of the controller 240. For example, the precharge assembly 104 is integrated with the controller 240.

[0029] Controller 240 includes a main contactor driver 242 that controls the main contactor 102 and a precharge driver 244 that controls the precharge assembly 104. Controller 240 includes a microcontroller 246 for controlling the main contactor driver 242 and the precharge driver 244. The microcontroller 246 may be an integrated circuit (IC) designed to control the specific operation of the main contactor driver 242 and the precharge driver 244. The microcontroller 246 may include a processor, memory, and input / output (I / O) peripherals on a single chip. The microcontroller 246, the main contactor driver 242, and the precharge driver 244 may be surface-mounted to control circuit board 200. For example, the main contactor driver 242 and the precharge driver 244 may be soldered to pads on control circuit board 200. Control circuit board 200 supports the microcontroller 246, the main contactor driver 242, and the precharge driver 244 in secondary cavity 112. In various other embodiments, the main contactor driver 242 and / or the precharge driver 244 may be integrated with the microcontroller 246 on a single chip. In various embodiments, the controller 240 may include an AD converter for converting between analog and digital signals, such as for controlling the main contactor driver 242 and the precharge driver 244.

[0030] In an exemplary embodiment, controller 240 includes a trigger connector 248 electrically connected to control circuit board 200. Trigger connector 248 is configured to connect to vehicle controller 40 (e.g., Figure 1 (As shown) a trigger signal is received. For example, an electrical connector can be coupled to trigger connector 248. In various embodiments, trigger connector 248 can be a plug connector or a receptacle connector. The trigger signal is used by controller 240 to operate main contactor driver 242 and precharge driver 244. For example, upon receiving the trigger signal, the trigger signal is used to activate precharge driver 244 to charge precharge capacitor 38 before activating main contactor driver 242.

[0031] In an exemplary embodiment, the precharge switch 204 is a semiconductor switch. For example, the precharge switch 204 may be a MOSFET. In various other embodiments, the precharge switch 204 may be a triac or an insulated gate bipolar transistor (IGBT). In various other embodiments, the precharge switch may be a mechanical relay. The precharge switch 204 is coupled to a first side 206 of the control circuit board 200. The precharge resistor 202 is coupled to a second side 208 of the control circuit board 200. However, in an alternative embodiment, the precharge switch 204 and the precharge resistor 202 may be coupled to the same side of the control circuit board 200. The precharge switch 204 and the precharge resistor 202 may be surface-mounted to the control circuit board 200. For example, the precharge switch 204 and the precharge resistor 202 may be soldered to a pad on the control circuit board 200. The control circuit board 200, the precharge resistor 202, and the precharge switch 204 are loaded into a secondary cavity 112 of the housing 106 and secured in the secondary cavity 112 by a cover 119. The control circuit board 200 supports the pre-charge resistor 202 and the pre-charge switch 204 in the secondary cavity 112. The walls 108 and cover 119 of the housing 106 enclose the pre-charge assembly 104. Optionally, a seal may be provided between the cover 119 and the housing 106.

[0032] The power distribution unit 100 includes first and second pre-charge connection terminals 210 and 212. The first and second pre-charge connection terminals 210 and 212 are received in corresponding contact channels 180. The first and second pre-charge connection terminals 210 and 212 extend between a first end 214 and a second end 216, respectively. The first end 214 is coupled to a corresponding fixed contact 120. For example, the first end 214 may include a ring 218 receiving a termination end 130. A nut may be used to connect the first end 214 to the fixed contact 120. A wire or busbar is configured to terminate at the termination end 130 of the fixed contact 120 and / or the first end 214 of the pre-charge connection terminals 210 and 212. The second end 216 is coupled to a control circuit board 200. For example, the second end 216 may include a pin or tail configured to press-fit into the control circuit board 200. The first and second pre-charge connection terminals 210 and 212 provide power to the power circuitry of the control circuit board 200 and the pre-charge driver 244. The precharge driver 244 is operable to supply power to the precharge switch 204. The precharge switch 204 is electrically connected to the fixed contact 120 via precharge connection terminals 210, 212 without the need for wiring between them. Assembly of the power distribution unit 100 is quick and easy, eliminating the need for separate wiring or busbars between components. The precharge connection terminals 210, 212 are quickly and easily connected to the fixed contact 120 to supply power to the precharge assembly 104. For example, voltage or current can be used to activate the precharge switch 204.

[0033] The power distribution unit 100 includes a coil connection terminal 220. The coil connection terminal 220 is received in a corresponding contact channel 180. The coil connection terminal 220 extends between a first end 224 and a second end 226. The first end 224 is coupled to a coil 142. The second end 226 is coupled to a control circuit board 200. The coil connection terminal 220 is electrically connected to the power circuitry of the control circuit board 200. A main contactor driver 242 is activated to provide power to the coil 142 to operate the main contactor 102. The coil assembly 140 is operated by the output of the main contactor driver 242, which is transmitted at the coil connection terminal 220. For example, a voltage or current can be transmitted at the coil connection terminal 220 to activate the coil assembly 140.

[0034] Figure 4 This is a perspective view of a power distribution unit 100 according to an exemplary embodiment. During assembly, a main contactor 102 is received in a housing 106, and a pre-charging assembly 104 is received in the housing 106. A controller 240 is received in the housing 106 to operate the main contactor 102 and the pre-charging assembly 104. A cover 118 encloses the main contactor 102 in a main cavity 110. A cover 119 encloses the controller 240 and the pre-charging assembly 104 in a secondary cavity 112. A fixed contact 120 is exposed at its first end 160 for connection to a wire or busbar. A single connection provides power to both the main contactor 102 and the pre-charging assembly 104.

[0035] Controller 240 controls the power supply to the pre-charge switch 204 and the coil assembly 140. For example, controller 240 first supplies power to the pre-charge switch 204 to supply power to the capacitor 38 (e.g., Figure 1 The capacitor 38 is charged without supplying power to the main contactor 102. After the capacitor 38 is charged, the controller 240 turns off the pre-charge switch 204 and supplies power to the coil assembly 140 to activate the main contactor 102. In an exemplary embodiment, the electrical connector 250 is coupled to the power distribution unit 100 to provide a control or trigger signal to the controller 240. For example, the electrical connector 250 is coupled to the trigger connector 248 (as shown). Figure 3 (As shown), thus electrically connecting to controller 240. A control signal triggers the operation of power distribution unit 100. For example, when a control signal is received at controller 240, a pre-charging operation is initiated, and then the activation of main contactor 102 is initiated.

Claims

1. A power distribution unit (100), comprising: The outer shell (106) has a wall (108) defining a main cavity (110) and a secondary cavity (112). A main contactor (102) is received in the main cavity of the housing. The main contactor includes a first fixed contact and a second fixed contact (120) and a movable contact (122) movable between a mating position and an unmatting position. The movable contact engages the first fixed contact and the second fixed contact to electrically connect the first fixed contact and the second fixed contact in the mating position, and the movable contact is separated from the first fixed contact and the second fixed contact in the unmatting position. The main contactor includes a coil assembly (140) which is energized to move the movable contact between the unmatting position and the mating position. A pre-charge assembly (104) is received in the secondary cavity of the housing, the pre-charge assembly including a pre-charge resistor (202) and a pre-charge switch (204) connected to the pre-charge resistor. as well as A controller (240) is received in the housing, the controller including a main contactor driver (242) that powers the main contactor (102), and a precharge driver (244) that powers the precharge switch (204). The outer casing (106) is a single-piece casing, and the wall (108) includes a partition wall (114) located between the main cavity (110) and the secondary cavity (112), with a first side facing the main cavity (110) and a second side facing the secondary cavity (112), wherein a contact channel (180) is located in the partition wall (114), and the contact channel (180) allows the contact to pass between the main cavity (110) and the secondary cavity (112).

2. The power distribution unit (100) as described in claim 1, wherein, The precharge switch (204) is a semiconductor switch.

3. The power distribution unit (100) as described in claim 1, wherein, The pre-charge resistor (202) and the pre-charge switch (204) are mounted on the control circuit board (200) of the controller (240).

4. The power distribution unit (100) as described in claim 1, wherein, The controller (240) includes a microcontroller (246) mounted to a control circuit board (200), the microcontroller being operatively coupled to the main contactor driver (242) and operatively coupled to the precharge driver (244), wherein the microcontroller activates the precharge driver to charge the precharge capacitor (38) upon receiving a trigger signal before activating the main contactor driver.

5. The power distribution unit (100) as described in claim 1, wherein, The controller (240) includes a trigger connector (248) electrically connected to a control circuit board (200), the trigger connector being configured to receive a trigger signal from a vehicle controller (40), the controller including a microcontroller (246) operably coupled to the main contactor driver (242) and operably coupled to the precharge driver (244), wherein, prior to activating the main contactor driver, the microcontroller activates the precharge driver upon receiving the trigger signal to charge a precharge capacitor (38).

6. The power distribution unit (100) as described in claim 1, wherein, The main contactor driver (242) and the precharge driver (244) are mounted on the same side of the control circuit board (200) of the controller (240).

7. The power distribution unit (100) of claim 1, wherein the controller (240) includes a power circuit on a control circuit board (200) electrically connected to the main contactor driver (242) and electrically connected to the precharge driver (244).

8. The power distribution unit (100) of claim 1, wherein the pre-charging component (104) includes a first pre-charging connection terminal (210) and a second pre-charging connection terminal (212), the first pre-charging connection terminal being connected to the first fixed contact (120) and to the control circuit board (200), the second pre-charging connection terminal being connected to the second fixed contact and to the control circuit board, the first pre-charging connection terminal and the second pre-charging connection terminal being electrically connected to the pre-charging driver (244), wherein the first pre-charging connection terminal and the second pre-charging connection terminal provide power to the control circuit board to operate the pre-charging driver.

9. The power distribution unit (100) of claim 8 further includes a coil connection terminal (220) connected to the coil assembly (140) and the control circuit board (200), the coil connection terminal being electrically connected to the main contactor driver (242), the coil connection terminal providing power to the coil assembly to activate the main contactor (102) and move the movable contact (122) to the mating position.

10. The power distribution unit (100) as claimed in claim 8, wherein, The first precharge connection terminal (210) and the second precharge connection terminal (212) are received in the corresponding contact channels.

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